Professional Documents
Culture Documents
P6003CON01L
P6003CON01L
P6003CON01L
General/Safety Information 4
Signal Words 4
Personal Safety 4
Welding Instructions 5
Tooth Systems
Helilok Tooth System Point Installation & Removal for Vertalok Adapters 19
® ®
Helilok Tooth System Point Installation & Removal for Helilok Adapters 20
Lip Systems
Ripper Systems
The purpose of this manual is to provide detailed instructions on the use and maintenance of ESCO construction ground
engaging tools. Please read the Safety Instructions section prior to performing any work in this manual.
Safety and Warnings
General/Safety Information
The safety practices described in this manual are meant as guidelines for safe operation under most conditions and are
meant to supplement any safety rules and/or laws that may be in force in your area. Your safety and the safety of others
results from putting into practice your knowledge of the correct operating procedures.
Signal Words
Throughout this manual are statements preceded by a special attention symbol: The symbol is used with the following
signal words to attract your attention to information of special priority. Read the paragraphs carefully and make sure you
understand their significance, especially the possible causes of injury.
WARNING: A statement preceded by “WARNING” is information that should be acted upon to prevent serious injury.
CAUTION: A statement preceded by “CAUTION” is information that should be acted upon to prevent machine or
equipment damage.
Additional signal words that are not preceded by the attention symbol are:
IMPORTANT: A statement preceded by the word “IMPORTANT” is information that possesses special
significance.
Tip: A statement preceded by “Tip” is information that is handy to know and may make your job easier.
Personal Safety
WARNING: When performing the work described in these instructions, always work safely and use proper safety
equipment to help avoid injury. Always wear hard hat, gloves, safety shoes, eye protection, hearing protection and fall
protection per regional, national and site requirements (e.g., OSHA, MSHA) when performing maintenance work. To avoid
injury to others, keep bystanders well out of the way.
3
Welding Instructions
ESCO Alloys
ESCO Series 12 alloys are used to provide strength and hardness to a variety of ESCO mining, construction, industrial and
dredging tools. They have been developed for toughness, with hardness ranging from 229‑550 BHN. Most ESCO teeth,
adapters, rippers, blades and end bits are made of durable Series 12 alloys. Some are weldable and some are not.
ESCO Series 14 alloy castings are manganese steels which work-harden on impact and thus maintain surface hardness
and wear resistance. ESCO Series 14 alloys are used in select bucket applications, such as shovel dipper doors, lips and
fronts, bushings, and other applications.
By following the welding instructions in this brochure you should have no difficulty welding and maintaining ESCO
products. If questions arise that are not fully answered here, please contact your ESCO dealer or call ESCO direct at one
of the locations listed on the back of this brochure.
Acceptance Standard
The following requirements apply to any one layer of weld, including root and final. One layer is generally intended to mean
a single plane of weld stringer beads, but suitable interpretation must be used if the shape results in a curving layer.
Linear Discontinuity
No cracks, including crater cracks, are allowed in welds or heat affected zones. No other linear discontinuity in these areas
shall exceed 6mm/0.25in. in length.
Porosity
Porosity shall not exceed (4) holes in every 100mm/4.00in. of length of a single weld bead. No single void shall exceed
1.50mm/0.06in. in diameter.
Slag
No visual slag in any layer is allowed.
Undercutting
Undercutting shall not exceed 1.50mm/0.06in. for material over 13mm/0.50in. in thickness.
Rollover
Rollover or weld overlap shall not exceed 1.50mm/0.06in. beyond the fusion line of the weld.
Weld Spatter
No bead of weld spatter shall exceed 0.8mm/0.03in. in diameter. The scatter density of beads of acceptable size shall not
exceed 25 per 230 sq. cm./36 sq. in.
Grinding
Grinding requirements shall be as specified on the applicable drawing. If grinding must be performed in only certain
directions, these requirements will also be specified on the drawing.
4
Welding Instructions
Refer to and follow the recommendations of the specific overlay plate manufacturer for proper overlay plate
design, installation, and maintenance. Cases may exist where the recommendations of the overlay plate
manufacturer conflict with ESCO requirements or procedures. If a conflict exists, follow the ESCO requirements.
Uses for ESCO Series 12 Alloys
Structural parts in these alloys can be hardfaced, but this is
Alloy Weldability Product Applications generally unnecessary because of wear shrouds that ESCO
provides to protect high wear areas.
12E (low Bucket lips and The alloy type is prominently marked on all ESCO cast
Good parts: 12S, 12K, etc. In cases where extreme wear has
hardness) structural components
obliterated the markings, Series 12 alloys can be
12E (high Bolt-on or shank type identified by their magnetism; Series 14 manganese alloys
Fair
hardness) adapters are nonmagnetic.
12F (low Bucket lips and Recommended Welding Procedures for
Good
hardness) structural components Series 12 Alloys
Follow these procedures for best results when welding
12F (high Bolt-on or shank type the weldable Series 12 alloys together or to other low alloy
Fair
hardness) adapters castings, carbon steel castings, forgings, or plate.
Front end loader
12C Good Use filler material as specified in the table on the back page:
weld-on adapters
Not Large points and • Control the moisture in low hydrogen electrodes by
12H purchasing electrodes in 4.5kg/10lb. sealed packages.
Recommended adapters
Larger packages invite moisture contamination which can
Not result in inferior welds.
12K Points and wearparts
Recommended • Bake previously opened packages of electrodes in a
ventilated oven at 260°C/500°F for two hours before
12M (low Structural parts for using.
Good
hardness) smaller buckets • Remove only one hour’s supply at a time. Keep the
remainder in a ventilated holding oven at 65°C/150°F.
12M (high Not Bolt-on adapters
hardness) Recommended and wearparts • Electrodes taken from cardboard boxes or non-airtight
containers should also be heated to 260°C/500°F for two
Not hours in a ventilated oven. Then they should be placed
12S Points and wearparts
Recommended in a ventilated holding oven set at 65°C/150°F while still
warm. Remove only one hour’s supply at a time.
Structural parts for • Any electrode exposed to the air for more than one hour
12T Very Good
larger buckets should be rebaked per the instructions above.
• Preheat and interpass temperatures are in the table in the
back of this booklet.
How to Weld ESCO Series 12 Alloys • When welding, use short stringer beads and remove slag
Certain Series 12 alloys are not meant to be welded. See after each pass.
chart above. Welding can destroy the heat treatment given • Bevel joints to get 100% weld penetration, when possible.
these parts, and cause inferior performance or failure.
As a rule, ESCO points should never be welded, repaired, or
hardfaced. They are manufactured as hard as possible.
ESCO alloys 12E, 12C, 12M and 12T have excellent
weldability. They are used for weld-on adapters, as well as
structural parts such as dragline bucket lips, cheeks and
arches; shovel dipper beams, lips and fronts; and dredge
cutter arms, rings and hubs.
5
Welding Instructions
Dot Hardfacing ESCO Series 12 Alloys • Dots serve as good wear indicators. Reweld them before
they are completely worn off.
ESCO does not recommend hardfacing ESCO Series 12
alloys. However, if hardfacing is performed, dot hardfacing • Use Stoody 31 or equivalent electrodes for hardfacing.
is recommended over other methods. • Always rebuild worn areas to the original contour with
an appropriate base filler material before hardfacing. If
Dot welding is faster, uses less material, and costs less wear is very deep or excessive, buildup with low alloy
than continuous beads or solid overlays. It also reduces the steel plate to original contour, then use the dot hardfacing
chance of cracking and weld failure that is common with method described above.
other methods.
• Apply dots about 10‑12mm/0.38‑0.50in. in diameter
welded in rows about 25-37mm/1.00-1.50in. apart.
6
Ultralok Tooth System Installation & Removal
®
General/Safety
Information
The practices described in this manual
are meant as guidelines for safe
operation under most conditions and
are meant to supplement any safety
rules and/or laws which may be in
force in your area. Your safety and the
safety of others results from putting
into practice your knowledge of the
correct operating procedures.
IMPORTANT: ESCO’s warranty is void when points and adapters have been
weld-repaired or hardfaced.
Step 1 – Clean the lock cavity of fines Step 2 – Insert the pry bar into the Step 3 – Insert the pry bar into the
on the top and bottom of the lock. top side of the lock and rotate the pry second groove and again push the pry
bar upward and toward the centerline bar toward the centerline of the point
of the point. Clean the fines from the until all three grooves are visible. The
second groove in the lock that is now lock will still be attached to the
exposed. point.
7
Ultralok Tooth System Removal Continued
®
Step 4 – In some applications, packed Step 5 – Once the point is loose on Step 6 – Clean the nose of fines and
fines may inhibit point removal. Use the the nose, slide the point off. dirt. After cleaning, inspect the nose
pry bar at the rear shoulder of the point for excess wear and peening. If
to work it loose from the fines. necessary, weld-repair or replace the
adapter to ensure trouble free
performance.
Step 1 – Install the new point onto Step 2 – Insert the pry bar into the Step 3 – In the fully locked position,
the nose. Make sure the lock is in the lower side of the lock and the point the lock face will be recessed from the
unlatched position before installing. wall. Push the pry bar toward the surface of the point.
centerline of the point until the lock
clicks into place. The distinctive click Note: Once all of the points are
ensures the lock is properly installed. replaced, double-check to be sure all
locks are fully installed.
8
Weld Rebuild of the Ultralok Nose
®
Recommended Materials:
1. Wire brush
2. Pre-heating device (i.e. gas torch, induction blanket)
3. Arc welder
4. Filler material/electrodes
5. Grinder End of Lock slot
nose
6. Aerosol stencil ink or white spray paint
7. New Ultralok point and lock
Figure 1
9
Installing a Continuous Edge with the Ultralok System
®
A continuous edge can be useful in applications when it is necessary to finish with a smooth surface or to increase
capacity of the bucket. Welding on ESCO points is not recommended. However, if a continuous edge is necessary for the
application, the following welding practices should be used.
A continuous edge should only be welded onto two or three parallel tooth positions. If too many positions are welded,
point/edge removal may become difficult. Do not weld to corner positions if they are canted outward.
To avoid cracking commonly associated with welding steel at the hardness level of Ultralok points, it is critical that the
preheat and interpass temperatures are followed as noted in the recommended welding parameters listed below.
Installation Procedure
Step 1 – Position the continuous edge across the teeth
to determine where welds should be placed. Please note: Weld both
even the points which are not welded provide support to the Do not sides of point
continuous edge. Refer to Figure 1 for recommended weld weld here Continuous
locations. edge plate
10
Installing ESCO Weld-on Adapters
CAUTION: ESCO weld-on adapters are hardened Weld-on Adapter Installation
typically to 415 BHN. In order to eliminate cracking 1. Locate the adapters on a clean bucket. Tack-weld them
commonly associated with welding steel at these hardness in place, followed by a root layer all the way around. Peen
levels, follow these procedures carefully and employ good weld after each pass. Do not weld to leading edge of lip.
welding techniques and practices.
2. Blend welds concave to remove stress concentrations as
Summary of Welding Specifications shown in Figure 1.
3. Turn the bucket over.
See weld recommendations on page 5.
• Electrodes: E7016 or E7018 low hydrogen (keep dry!)
• Wires: E70T-5, E71T-1, or E70T-1 with CO2 gas. Weld Grinding
Weld
• Preheat: 95°C/200°F (175-205°C/350-400°F if air Adapter stone
temperature is 5°C/40°F or lower.)
• Interpass: Maintain interpass temperature less than Blend
260°C/500°F. grind Hold weld back Lip
from leading edge
• Post-heat: If air temperature is 5°C/40°F or lower,
post-heat 175-205°C/350-400°F, then let air cool.
• Remove slag after each pass and peen each bead. Figure 1
Welds should fill J-grooves to a J-groove Concave CAUTION: To prevent cracking, welds should never
45° angle. If an adapter does not weld, never be extended to the leading edge of the lip. Terminate, and
Adapter convex
have a J-groove, apply fillet welds blend grind, the ends of the upper leg weld at the end of the
according to the following: J-groove weld prep. Refer to Figure 1.
Lip 45°
4. For one-leg Flushmount Adapters, a fillet weld of equal
Bucket Size (volume) size to the leading edge thickness of the lip should be
applied. Grind the ends smooth at weld junctions. If a
Meter3 Yards3 Fillet Size lightener cavity extends forward of the lip leading edge,
1.8 2 13mm/0.50in. cover the opening with weld. Maintain a full fillet width on
the entire weld shown in Figure 2.
2-4.6 2.25-5 16mm/0.63in.
5-11 5.5-12 19mm/0.75in.
above 11 above 12 25mm/1.00in.
Additional welding information can be found on page 5 of
this book.
Blend grind
Figure 2
Continued on the next page.
11
Installing ESCO Weld-on Adapters, Continued
Weld-on Corner Modification and Installation
Typical Wheel Loader
Protection of the corner of your bucket will increase its life. Installation
Adapters can be modified to provide protection by cutting Top views
to fit bucket side plates. A bucket should never be cut
to fit an adapter!
The corner adapter should be positioned so the point cuts Sideplate
clearance for the bucket. Trim adapter upper leg to fit
and protect the sideplate.
If a clean trench is desired, corner adapters can be
mounted so points are positioned flush with the outside of
the bucket. Never remove more
Typical Excavator than 50% of adapter leg.
When modifying an adapter, never remove more than Installation
50% of the adapter top leg. The edges of the cuts Adjust for desired
should be chamfered 13mm/0.50 in. x 30° for weld tipout angle
preparation as shown in Figure 3. Sideplate
Follow welding procedures described above in Adapter
Installation. Bevel adapter 30° x
13mm / 0.50in. for
Install points according to ESCO Point Installation and weld prep. (typ)
Removal Instructions.
Figure 3
12
Installing ESCO Bolt-on Adapters
Recommended Hardware The lip contact requirement applies to all bolt-on
• Grade 8 bolts adapter styles, including corner adapters.
• Grade 8 ESNA lock nuts
Ramp contact; max. gap
• Hardened steel washers (used on adapters with remaining: 2mm/0.09in.
elongated bolt holes).
Gap 0.12in. max. gap,
General Procedures
no interference
• Adapters must fit onto the lip easily; they should never be
forced on. Lip
Adapters designed for
• There should be a maximum clear gap of 3mm/0.12in., lip bevel contact.
between the adapter leg and the bucket lip (cutting edge).
• When in position on the lip and with bolts installed,
adapters must contact the lip leading edge (lip blunt) or Ramp contact Lip contact must be maintained
the lip bevel, depending on the adapter style, see Figure with bolts installed to ensure bolts
1. do not carry thrust loads. If the
• Bolts should be installed so their heads fit into recesses adapter is not in contact with the
cast in the adapter legs, see Figure 2. lip and the bolts are carrying the
Corner adapter load, then it is necessary to
• Tighten bolts securing an adapter alternately. Then apply weld-rebuild the lip leading edge.
final torque, rear bolt first, front bolt(s) last. The correct
tightening sequence is important because the front bolt Gap
may loosen if the rear bolt is brought to final torque last.
Check torque values in chart below. 0.12in. max. gap,
no interference
CAUTION: Retorque bolts after approximately four hours
of service. Leading edge Lip
contact
• Periodically check bolt torque. Insufficient adapter bolt
torque can result in adapter failure in heavy-duty
applications. Figure 1
13
How to Install Weld-on Noses
When a nose is worn out it is recommended that the adapter be replaced. There are instances where using a weld-on nose
is a viable alternative. For instance, buckets with cast corners. Another example is an old machine that adapters are no
longer available and the customer wishes to convert to a newer system.
Procedures
1. Hold the weld-on nose in place along side the nose to Run out plate
be replaced. With the end of the noses lined up, mark Top view
the spot where the weld groove of the weld-on nose is
located relative to the nose to be replaced. Cut the old
nose off at this location, angled back from where the
weld-on nose weld prep contacts the surface. This allows Base
a little extra room to get the welding rod in at the proper
angle. If the nose is cut off with a torch or air arc, be sure
to grind the surface down to clean parent metal, removing
all foreign materials.
2. If replacing only one nose, tack weld a straight edge to Tack welds
the adjacent nose to assist in properly locating the new Weld-on Nose
nose. If replacing all the noses, it is best to tack weld a
straight edge across the outside positions, remove the 3mm / 0.12in.
center noses and weld the new noses in place. Then
tack weld the straight edge to the center noses, cut off
the outside noses and replace using the straight edge to
insure proper location. Base
Note: Digging performance can be greatly affected by
improper nose angles so it is important to maintain the Side view
original nose position.
3. After the old nose is removed and the surface prepped,
tack weld starter plates to the outside of each end of the
weld prep. Then use the run-out plates to tack weld the
nose in place to the base (see illustrations), leaving about
a 3mm/0.12in. gap between the weld prep and the base.
Check to be sure the weld-on nose is lined up to the
adjacent noses.
4. Preheat the assembly to 177°C/350°F to 204°C/400°F.
Check with Tempilstick before welding. Preheat before
starting any additional welding if the castings have cooled.
5. Apply weld bead across the length of the weld prep,
starting and stopping on the run-out plates. After a few
passes, peening between each pass, turn the bucket over
and grind the root pass to remove any impurities,
cleaning down to solid weld material. Again, apply several
weld beads across the length, starting and stopping on
the run-out plates, and peening between each pass.
Alternate running several weld passes from side to side
until the weld area is filled.
6. Burn off the run-out plates and grind the entire weld
surface smooth and as close to the original contour as
possible. WARNING: When performing the work
described in these instructions, always work safely
and use proper safety equipment to help avoid
injury. Always wear hard hat, gloves, safety shoes,
eye protection, hearing protection and fall
protection per regional, national and site
requirements (e.g., OSHA, MSHA) when
performing maintenance work. To avoid injury to
others, keep bystanders well out of the way.
14
Installing Super V Points and Pins ®
1. Slide the point in place on the 2. Place the pin into the nose and 3. Drive the top of the pin flush with
adapter nose. Install the point with a point ear opening as shown. the top of the point ear using
clockwise quarter turn. The bottom moderate taps from a hammer
of the point cavity must fit solidly (see Hammer Size chart below
against the end of the nose. for correct size). The pin lock plug
will compress as it passes the top
of the ear and then snap into the
ear lock recess. To assure proper
Note: V13 and V17 points are non-twist and slip directly onto the nose. engagement of the lock plug with
Note: Super V pins can only be used with Super V points and adapters. the ear lock recess, do not over or
under drive the top of the pin.
Removal
1. Place removal tool on top of 2. Remove the point 3. Clean the nose
pin and drive out
Removal Tool WARNING: The bucket should be Inspecting the Pin for Reuse
Sizes Removal Tool level or with teeth slightly upward to
prevent the teeth from falling off after End Wear or Bending
V13-V33 V13-V33RT pin removal.
V39-V61 V39-V61RT IMPORTANT: If the pin is
PDE49873-1 Short WARNING: Never hammer on an bent more than 3mm/0.12in.
V69-V81 edge or a corner of the point. Doing so or is obviously deformed,
PDE49873-2 Long it should be replaced.
could produce flying shards of metal.
Hammer Size Comparing to a new pin is
the best way to determine if
SUPER V Hammer Wt. the pin should be replaced. If
Size kg/lb. pin is excessively peened or
V13-V43 1-2/2-4 mushroomed, dress before
V51-V61 2-4/4-8 use.
V69-V81 2-4/4-8
15
For V51PN, V59PN, and V61PN
Installation
2. Install 3. Locating the pin in position
1. Slide on
the wear cap the point Top of pin flush with
top of point ear
(if used)
Lock plug
engaged
with
ear lock
recess
1. If a wearcap is to be installed, 2. Install the point with a clockwise 3. Place the pin into the nose and
slide it in place in the slots on the quarter turn. The bottom of the point ear opening. Drive the top
adapter’s upper surface. point cavity must fit solidly against of the pin flush with the top of the
Note: Super V pins can only be used the end of the nose. Before reusing point ear using moderate taps from
with Super V points and adapters. a pin as follows in step 3, the pin a 2-4 kg/4-8 lb. hammer. The pin
should be inspected as shown lock plug will compress as it passes
below. the top of the ear and then snap
into the ear lock recess. To assure
proper engagement of the lock plug
with the ear lock recess, do not
over or under drive the pin.
Removal
1. Drive out the pin. ESCO 2. Remove the point with a 3. Clean the nose so the new
recommends using a Pin Removal counterclockwise quarter turn. It point will fit in place solidly and
Tool (refer to the chart below for may be necessary to tap the side completely. If a wearcap is to be
the correct size). Begin the removal of the point to loosen impacted installed, make sure the wearcap
with the short shaft of the tool, fines. Use a brass or rubber mallet. slots are clean. Reversible
then finish with the long shaft. If a Slide off the wearcap if it is to be wearcaps should be rotated with
Removal Tool is not available, use a replaced. each tooth change to balance
punch or a drift pin. wear and to keep from becoming
wedged.
Inspecting the Pin for Reuse on the next page.
Removal Tool
Sizes Removal Tool
V51-V61 V39-V61RT
V69-V81 PDE49873-1 Short WARNING: When performing the work
described in these instructions, always work safely
V69-V81 PDE49873-2 Long
and use proper safety equipment to help avoid
injury. Always wear hard hat, gloves, safety shoes,
eye protection, hearing protection and fall
protection per regional, national and site
requirements (e.g., OSHA, MSHA) when
performing maintenance work. To avoid injury to
others, keep bystanders well out of the way.
16
Installing Super V Points and Pins, Continued
®
1. Excessive end wear or bending 2. Missing lock or take up plug 3. Plug does not extend fully or
Maximum wear line is damaged
Missing or Missing or
damaged damaged
take up lock plug
plug
Impacted fines cause
a gap of more than
1.5mm/0.06in.
17
Helilok Tooth System Installation & Removal
®
C
F
E
B
A
D
1. The Helilok point (A) twists onto 2. Clean the adapter nose to make 3. Check used plugs for torn, cracked
the adapter (B) and is secured by sure the point will fully seat. or separated rubber.
the pin (C) and plug (D). The plug Note: Plugs for Hot Slag applications
(D) is inserted into the adapter, are not encased in rubber.
and the pin (C), is driven in from Replace the plug if damage is
the top. The recommended tools
for installation and removal are a discovered. With fines removed from
removal tool (E) and a hammer the hole, insert the plug, making sure it
(F) of the appropriate weight, as seats fully on the bottom of the hole. The
follows: For nose sizes 27V, 37V, shoulder of the plug should be no deeper
47V, use a 1-2 kg/2-4lb. hammer. than the depth shown in Figure 3 at the
For nose size 57V use a 2-3 kg/4-6 following dimensions: For nose sizes
lb. hammer. 27V, 37V, 47V, maximum allowable depth
is 3.2mm/0.12 in. For nose size 57V,
maximum allowable depth is 4.8mm/0.19
in.
Recess Flush
Bevel Upper pin
Pin
retainer
Pin
Lower pin
retainer
4. Twist the point on with a quar- 5. Inspect the top of used pins. It 6. Start the pin with a swift, sharp
ter turn to contact the end of the should be free of sharp edges blow with the hammer. If the pin
adapter nose. Check the lock due to wear or peening. If there becomes crooked after the
groove to be sure the plug remains are sharp edges, replace the pin: first blow, straighten it before
fully seated. Also replace the pin if the recess proceeding. Drive the pin in until the
is distorted or the pin has flattened top is flush with the top of the upper
out (compare to a new pin). Both pin retaining ear (located on the
may cause premature pin ejection. adapter nose on 27V, 37V, 47V, and
Insert the pin with the bevel down 57V sizes).
and the recess to the inside so the
recess can engage the plug tip.
IMPORTANT: The pin is marked with an arrow which must point downward.
Removal
1. Place the small end of the Removal 2. Complete the drive with the long 3. Remove the point by twisting
Tool on the top of the pin and start end of the Removal Tool until the counter-clockwise. Make sure the
the drive with the hammer. It may pin comes out the bottom. When plug is fully seated so the point ear
take a few solid blows. removing the Tool from the groove, can pass. May require a few taps
be careful not to dislodge the point. with a brass or rubber mallet to
WARNING: The bucket should be loosen impacted fines.
level or with teeth slightly upward to Vertalok pin Removal Tool
prevent the teeth from falling off after pin Pattern Wt.
removal. Description
Number kg/lb
WARNING: Never hammer on an CD18436#2 1.5/3.2 Tool for 27V Series
edge or a corner of the point. Doing 37V/57V 2.0/4.5 Tool for 37V, 47V, and 57V Series
so could produce flying shards of metal.
18
Helilok Tooth System Installation & Removal, Continued
®
D E
B
A
C
1. The Helilok point (A) threads onto 2. Clean the adapter nose to make 3. Twist the point on with a quarter
the adapter (B) and is secured by sure the point will seat fully. turn to contact the square end of
the U-shaped Quadrilok® (C). The the adapter nose.
tools required for installation and
removal are a 4 lb. hammer (D) and
ESCO Quadrilok removal tool (E).
4. Insert the Quadrilok with the side 5. Center the Quadrilok between the 6. To complete installation, check
marked “FRONT” facing the front of point ears. Then tap the top of the that the hooks on both legs of the
the point. Always use a new U-shaped lock to seat it fully into Quadrilok are fully secured under
Quadrilok when changing points. the groove. the point ears.
Removal
1. Tap the sides of both point ears 2. Use a screwdriver to clean the 3. Insert the small hooked end of the
with a brass or rubber mallet to recess slot in the center front of the removal tool under the Quadrilok
loosen impacted fines. Quadrilok. and apply a sharp downward tug to
initiate removal.
4. At mid-point of lock removal, insert the 5. If the Quadrilok binds, complete the 6. Remove the Quadrilok. Complete
large jaw end of the removal tool under removal by tapping the lock on both removal by pulling the point off the
the Quadrilok to obtain extra lever- sides while maintaining pressure. adapter with a 1/4 twist.
age. Additional blows on the point and
downward pressure on the tool will aid
in lock removal.
Quadrilok Removal Tools for Helilok Adapters
WARNING: The ESCO removal tool is Pattern (L) Length Weight Comments
designed only for use with Helilok points and No. mm/in kg/lb
adapters.
27/21 (long) 787/31.0 2.3/5.0 Tool for 21 & 27 Series
WARNING: Never hammer on an edge 27/21S (short) 648/25.5 1.9/4.2 Tool for 21 & 27 Series
or a corner of the point. Doing so could 552512 (long) 1016/40.0 4.1/9.0 Tool for 37, 47, & 57 Series
produce flying shards of metal. 552803 (short) 864/34.0 3.8/8.3 Tool for 37 & 47 Series
19
Installing & Removing Horn-Style Adapters
1. Before installing the adapter, make sure all mating
surfaces between the adapter and lip are clean. W1 fluted spool
Surface A, equal and wedge
2. Fit the new adapter in place on the lip and check bearing top and bottom
clearances. The adapter must bear fully on the tapered Gap D
surfaces of the tooth horns (Surface A), equally top and Shank type adapter
bottom, see Figure 1.
Gap B 32-64mm/
The gap between the end of the tooth horn and the 3-9mm/
adapter Gap B should be 3-9mm/0.12-0.38in., Gap C 1.25-2.50in.
0.12-0.38in.
should be about 0.8mm/0.03in. top and bottom. Gap
D should be at least twice Gap B top and bottom. See Gap C,
Figure 1. 0.8mm/0.03in.
top and bottom
If these clearances are not achieved, tooth horn rebuilding Tooth Gap D (at least twice
may be needed. Refer to the instructions following this horn Gap B, top and bottom)
section.
Figure 1
3. Insert the fluted spool into the forward end of the keyslot
with the larger lug down and facing forward. See Figure 2.
4. Insert the fluted wedge behind the spool with the large Fluted wedge
end up. Drive the wedge until it moves no further after Fluted spool
repeated solid blows with a hammer. Use 1.8 kg/4 lb. on Gap E
C19 size, and 3.6 kg/8 lb. on C29 size and larger, see Tooth horn
Adapter
Figure 2.
20
Installing & Removing Zipper Lip Adapters & Shrouds
®
21
Adapter Installation & Removal with
Alternately drive downward and
the Fluted C-Clamp & Wedge rearward to prevent rotation
A fluted c-clamp and wedge locking system secures an
adapter to the Zipper Lip system by the friction produced Optional tack weld
Adapter
between the mating flutes of the two components. C-clamp
Install a fluted c-clamp and wedge according to the Must
following, see Figure 2: be a
butt fit
1. Fit the adapter in place onto the Zipper Lip system,
making sure there is a butt fit between the adapter and Zipper
the leading edge bearing pad of the Zipper Lip base. Lip base
Zipper Lip base
2. From the inside of the bucket, insert the C-clamp into the leading edge Burn off any portion of
rear of the keyslot with the flutes forward and the narrow bearing pad the wedge that extends
end up. below the adapter
3. Insert the wedge into the keyslot, narrow end down. The
flutes of the wedge must mate with those of the c-clamp.
Figure 2
4. Drive the wedge in place with a 4.5-6.8 kg/10-15 lb.
hammer. As the wedge seats, hit it from the front to make
sure the c-clamp/wedge assembly does not rotate or bind
in the keyslot. Continue driving the wedge alternately
downward and rearward until the wedge no longer moves
when struck from the front. The wedge is now seated.
5. Burn off any portion of the wedge that extends below the Adapter support 160R Adapter support
adapter. all except 160R
6. After 2 to 3 hours of operation, check the wedge for
tightness. Burn off any portion of the wedge that extends
down after reseating.
7. When tightening is no longer required, the c-clamp
and wedge may be tack welded together for additional
security, see Figure 2.
8. If a W1 (standard) wedge drives flush with the adapter,
install a W2 (oversize) wedge. If a W2 wedge drives flush Leading edge tab Parallel rails
with the adapter or when adapters have excess side-to-
side movement (more than 13mm/0.50in.), weld-repair of Figure 3
the lip is needed. Refer to the next section for
recommended weld-repair procedures.
Note: Adapter support on all Zipper Lip series except
160R is provided by tabs that extend forward of the lip
leading edge. Adapter support on 160R Zipper Lips only
is provided by parallel rails that flank the adapter legs, see
Figure 3.
IMPORTANT: When wear edges are installed and
adapters secured, the wear edges should be slightly loose
on the lip.
9. When wear edges have excessive side-to-side movement
(more than 13mm/0.50in.) on an individual wear edge or
more than (9mm/0.38in.) on all wear edges, weld-repair to
the Zipper Lip system is recommended. Refer to the next
section for recommended weld-repair.
WARNING: When performing the work
Periodic Maintenance described in these instructions, always work safely
The Zipper Lip wear parts are cast from alloys that provide and use proper safety equipment to help avoid
maximum strength and wear life. As parts wear out, they injury. Always wear hard hat, gloves, safety shoes,
should be replaced with new ones; welding wearparts is not eye protection, hearing protection and fall
recommended (refer to warranty).
protection per regional, national and site
Note: For recommended welding procedures and requirements (e.g., OSHA, MSHA) when
materials, refer to page 5. performing maintenance work. To avoid injury to
others, keep bystanders well out of the way.
22
Weld-repair for Zipper Lip Systems
®
pin. Before installing the point, clean the nose and pin hole
thoroughly with a wire brush. Next install the point onto the Shank mounting
nose and align the pin holes. Finally insert the pin into the pin holes
pin hole on the point and drive the pin in until it is flush using
a 2-4 lb. hammer.
Construction rippers use a pin and a snap ring (RC style) Pin and
or bushing (R style). For construction rippers, place the snap ring for
snap ring in the recess on the side of the nose (RC style) or construction
rippers Shroud
insert the bushing in the nose pin hole (R style).
To remove the point from the nose, drive the existing pin out
of the nose using the ESCO removal tool and remove the
point.
Note: Pins are not designed to pull points or shrouds
tight on shank.
Uni-Lok
Shroud Installation pin for
The shroud is held in place by two Uni-Lok pins. Install the mining
shroud by driving in the lower pin first, using a 2-4 lb. rippers
Ear recesses
hammer.
Uni-Lok pin Ripper nose
Remove the pins with a pin removal tool and a 2-4 lb.
hammer. Conical bearing
TM
Ripper flats
Check for Nose Wear
Point
Check the nose for wear periodically to help prevent point
loss and breakage. The best way to do this, is to cut a
window into the side of a new point as shown.
Hold this cutaway point on the nose Ramp
Cut out
and check the flats at the end of the section
nose, as well as the ear recesses
for wear. Also, check to see that the
conical nose surfaces bear against the
Continued on the next page.
box section of the point. Make sure
the point does not butt up against the
rear shoulder of the nose.
When wear on the flats are 3mm/0.13in. as measured
between the new point and the worn nose or if the bearing
is on the rear shoulder of the nose instead of the conical
surfaces, the nose should be replaced.
24
Installing ESCO Rippers and Rip-A-Pak™ Kits, Continued
Maintenance & Performance Problems 2. After the rebuild or if shank is not overly worn, place the
Rip-A-Pak replacement nose so back edges are lined up.
Shank breakage Mark the shank with a burn-off line using the Rip-A-Pak
1. Check to see if the clevis pocket is properly maintained replacement nose as a guide or select the proper burn-off
and the shank is securely attached. Wear should not leave angle from the chart below, see Figure 1.
a gap of more than 6mm/0.25in. per side. Shim or weld 3. Burn off broken section of the shank and burn weld bevel
buildup as needed. on each side, see Figure 2. Make a lip with weld beads
2. Has the shank been misused, such as backing up while along the point of bevel.
ripping or side slipping on a hill? 4. Align the weld-on nose so the bevel of the shank and
3. Has the machine been turning while the ripper is nose piece have a 3mm/0.13in. gap between them and
engaged in the ground? the forward edges are in line. Tack weld as shown in
Figure 2.
Shroud breakage 5. Preheat the assembly to 177°C/350°F, 204°C/400°F.
1. Check to see if shroud is worn out. Check with Tempilstick before welding. Preheat before
2. Has the proper ESCO point been used with the shroud? starting any additional welding if castings have cooled.
3. Change shrouds before the center part wears through or 6. Run a root bead the length of gap. Be sure to get 100%
the sides wear too thin to protect the shank. penetration. Remove all slag. Peen each bead lightly. Turn
the shank over, grind the root of the weld clean to sound
Point breakage or loss metal.
1. Is the nose worn beyond reasonable use? 7. Weld 2-3 beads on one side, removing slag and peen
2. Do ripping conditions require a shorter point? after each bead. Turn shank over and repeat until job
3. Is the ESCO point being used with the proper shroud? is completed. This procedure is necessary to keep
nose piece in proper alignment with the shank. Use
4. Is the machine backing up or turning while the ripper is in stringer beads only and weave not more than 3 times
the ground? the electrode diameter. DO NOT USE WIDE WASH
Check for worn pins BEADS!
The one-piece locking pins for shrouds are reusable, but 8. Remove porous metal that has accumulated at either end
should be inspected every time you change shrouds. If the of the weld by burning or grinding to solid metal. Remove
all notches or pockets in the metal, see
rubber bonding is loose or the metal inserts are bent or Figure 3.
become dislodged from the pin, install a new pin.
9. Grind or burn-off the rebuilt area until a smooth transition
Rip-A-Pak Kit Installation from shank to nose piece is obtained. The finished
surface should be as smooth as possible since stresses
Note: Use welding rod AWS E-7016 or E-7018 concentrate at any depressions or
5mm/0.19in. diameter. Be sure rod is completely dry. Refer irregularities.
to Welding Instructions on page 5. 10. Dye-check all exposed weld to detect cracks. All cracks
1. Place shank to be repaired on side, draw a line through must be ground to remove dye-check
the centerline of the shank mounting pin holes (see indications. Reweld, using outlined procedure.
illustration on previous page). If the pin holes are not 11. Torch heat the weld and areas adjacent to weld on both
on centerline of the shank body and shank is badly sides of shank to 177°C/350°F-204°C/400°F. Allow to air
worn back 50mm/2.00in. or more from original contour, cool slowly. Repeat Steps 7 and 8, if necessary.
rebuild worn areas.
3m
m/
0.1
35R: 28° 3in Tack weld
39R: 30° .g
ap
Rip-A-Pak Kits
35-6R WNS 39-5R WNS1 39-5R WNS2 39-5R WNS3 49-5R WNS 59-5R WNS
Nose Burn-Off Nose Burn-Off Nose Burn-Off Nose Burn-Off Nose Burn-Off Nose Burn-Off
Angle Angle Angle Angle Angle Angle Angle Angle Angle Angle Angle Angle
28° 31.6° 30° 35.5° 30° 35.7° 30° 35.7° 30° 35.6° 30° 34.7°
25
Installing ESCO Toolbox Rippers
Size / Break Out Force
V33 / 23,000 lb. or less
V39 / 30,000 lb. or less
V51 / 30,000–45,000 lb.
V59 / 45,000–64,000 lb. Bucket
top plate
Locating Rippers 45-55° Mounting 13mm /
Note: Illustration shows details as described pad 0.50in.
below. Mounting pad
Single toolbox rippers should be mounted on
the bucket’s centerline. Dual or multiple rippers Toolbox should
conform to Plug-weld 19mm / 0.75in.
should be mounted symmetrically about the bucket radius
centerline with corner installations no closer
slot
to the edge of the bucket than 13mm/0.50in.
Also, multiple rippers should be installed Toolbox 50mm / 2.00in.
Burn to
with the attachment pins aligned to ease blending
their installation and removal. radius Position to suit Mounting
material being pad
Generally, all rippers should be installed so ripped and 25mm / 1.00in.
that shanks are parallel to the bucket centerline. machine power 76mm /
However, corner rippers may be pitched outward 3.00in.
slightly to provide additional ripping width; left hand and at both
right-hand toolbox alterations will be required accordingly. ends
19mm / 0.75in. if
Mounting Pads 38mm / 1.50in. or more,
Each toolbox ripper should be welded to a mounting pad which may be plug-weld is required
either an existing bottom runner or a pad specially installed for the purpose
(mounting pads are not required on ESCO SHDC buckets).
Special mounting pads should be as thick as the runners, should extend at least 76mm/3.00in. above and below the tool
box, and should be formed to match the bucket’s profile. In addition, each pad should extend at least 19mm/0.75in. beyond
each side of the toolbox.
If the toolbox is to be mounted to a runner, material may have to be added adjacent to it in order to achieve this
19mm/0.75in. minimum. An ideal pad will fit snugly between runners. Install pads by welding both sides with a
full-depth groove weld and both ends with 13mm/0.50in. fillet weld.
Continued on the next page.
26
Installing ESCO Toolbox Rippers, Continued
27
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